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ZF synchromesh transmissions
16 S 151, 16 S 181
16 S 221, 16 S 251
1315 758 101e
Copyright by ZF
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Printed in Germany
ZF Friedrichshafen AG, MKS-K / 1992
Edition: 10.2001
Preface
Your vehicle is equipped with a synchromesh transmission of the ZF-ECOSPLIT model range.
The more familiar you are with the Ecosplit transmission, the more economically you will be able to drive
with it. These operating instructions inform you of how
to make the best use of the technical advantages of the
ZF transmission. Therefore, please carefully read these
operating instructions and any special instructions
provided by the
vehicle manufacturer before driving the vehicle for the
first time.
! DANGER
Non-observance of safety instructions may lead to
operational errors, damage to or destruction of the
unit. As a consequence, operators or other persons
may be injured or their life may be at risk.
NOTE
Refers to special processes, techniques, data, use of auxiliary
equipment, etc.
!
CAUTION
This is used when incorrect, unprofessional working practices may damage the product.
DANGER
This is used when lack of care may lead to
personal injury or death or damage to property.
Contents
Page
1
2
2.1
2.2
2.3
2.4
2.5
Description
Design .....................................................................
Configuration ..........................................................
Gearshift system ......................................................
Servoshift.................................................................
Auxiliary units .........................................................
5
5
7
9
9
3
3.1
3.2
3.3
3.3.1
3.3.2
3.3.3
3.4
3.4.1
3.4.2
3.5
3.6
3.7
Operation
Starting the engine and setting off...........................
Operating the clutch ................................................
Gear selection ..........................................................
Shift pattern .............................................................
Changing gear..........................................................
Changing gear with servoshift.................................
Engaging and disengaging PTOs.............................
Clutch-dependent PTOs...........................................
Engine-dependent PTOs ..........................................
Parking.....................................................................
Tow-starting.............................................................
Towing away ............................................................
10
10
11
11
13
15
16
16
17
17
17
18
Page
3.8
3.9
Maintenance
Transmission oil.......................................................
Oil grades.................................................................
Oil fill quantities......................................................
Oil change intervals .................................................
Oil change................................................................
Draining off old oil .................................................
Oil fill ......................................................................
Oil level check .........................................................
Maintenance of transmission (version
with heat exchanger)................................................
Checking clutch operation .......................................
Checking release valve at the clutch pedal .............
Transmission breather..............................................
Maintenance of the pneumatic system ....................
Type plate.................................................................
21
21
21
21
22
22
23
23
24
25
26
27
27
28
Technical data
Model
Input torque
max. Nm
Ratios
1)
16 S 151
16 S 181
16 S 221
16 S 251
1600 / 1850
1900 / 2200
2200 / 2500
2700
Forwards gears
13.80 - 0.84
Reverse gears
12.92 - 10.80
Speedometer
electronic
Installation2)
z=6
Horizontal, to the left with integrated clutch bell housing
Gearshift
4-speed section Forwards gears with synchromesh, reverse gear with constant mesh
Shift actuation
Range change group4) Double H: changeover conducted automatically with appropriate selection
Superimposed H: changeover using preselection switch on shift lever
Splitter group4) Preselector valve on shift lever
Weight (without auxiliaries) approx. kg
289
315
319
334
approx. l
11
13
13
13,5
approx. l
10
10
11
5)
Approximate value (depends on vehicle type and vehicle data as well as relevant application).
Here, the ZF Guidelines for installing manual transmissions (1203 765 110) should also be noted.
Turning shaft control connection can be adapted to the installation conditions in the vehicle.
Air pressure required = 6.2 to max. 10 bar; pressure red. valve (ZF no. 0501 204 036) must be fitted for higher pressure levels.
Transmission inclination 0 to 3
1315 758 101e
Description
Description
2.1
Design
Configuration
4-speed section:
synchromesh, reverse gear with constant mesh
manual shift control (turning shaft control)
double H shift pattern or superimposed H shift pattern
Servoshift
Range change group, rear-mounted:
synchromesh
automatic changeover (pneumatic) when shifting
between gates 3/4 and 5/6 or vice versa (Fig. 2)
with double H pattern
changeover using preselector switch on shift
lever with superimposed H pattern (Fig. 3a)
Selector pattern I
R
1-4
5-8
N
Selector pattern II
Selector pattern I
Selector pattern II
Description
Fig. 3
Double-H *
shift lever
Fig. 3a
Superimposed H *
shift lever
high
Range-change
group
high
low
high
high
tter
Spli
p
grou
Range-change
group
Splitter group
low
low
low
3
N
N
7
3
5
1
6
4
6
2
8
4
Description
2.3
Gearshift system
Range-change group, double H shift pattern
Fig. 4
ZF double H shift pattern
Fig. 4a
ZF superimposed H shift pattern
Description
35
Splitter group
The splitter group is operated by means of a toggle
switch fitted to the shift lever (Fig. 3 and 3a). The low or
high splitter group is preselected by the driver using this
switch and shifted when the clutch is depressed.
NOTE
Changeover is performed when the clutch is fully
depressed.
34
017853
Fig. 5
34 Pneumatic cylinder
35 Shift valve
Description
2.4 Servoshift
2.5
Auxiliary units
Depending on the vehicle configuration, the Ecosplit
transmission may be equipped with the following
auxiliary units (Fig. 7):
Shifting Ecosplit transmissions with Servoshift is performed as described under 2.3 (Fig. 4 and 4a), but with
pneumatic support.
Advantages are: considerably shorter gear lever
travel,
reduced shift forces
Fig. 7
WSK
Fig. 6
+ NMV
Vehicledependent
PTO
N ... PL
Clutch-dependent
PTOs
N1, N4 and N10
011359
017083
Integrated
ZF-Intarder
Enginedependent
PTO
NMV 221
Operation
Operation
3.1
15
25
5
0
20
10
rpm x 100
30
DANGER
When leaving the vehicle with the engine running,
activate parking brake. This prevents undesired vehicle
rolling.
3.2
React to traffic conditions
well in advance.
Avoid unnecessary braking
and accelerating.
10
CAUTION
Changing gear when the clutch is not fully disengaged
causes additional wear to the synchronizers in the transmission.
Operation
3.3
Gear selection
The gate for reverse gear is safeguarded by a springloaded stop and requires a greater amount of force to
overcome.
GP changeover 5
N
6
4
2
Double H
The double H shift pattern (Fig. 8) includes a springloaded neutral position (idling position) in gates 3/4 (low
range-change group) and 5/6 (high range-change group).
In order to select gears 1/2 or 7/8, move the selector lever
against the spring force in the required direction and hold
the lever against this force when making the engagement
stroke. The gear lever returns to the neutral position if
released in the central area. The slow range-change group
is separated with a stronger spring force (GP
changeover) than the high range-change group.
Fig. 8 Shift lever with double H shift pattern and splitter lever
11
Operation
Superimposed H
The superimposed H shift pattern (Fig. 8a) has a springloaded neutral position (idling position) in gates 3/4
(low range-change) and 7/8 (high range-change).
In order to select gears 1/2 or 5/6, move the
selector lever against the spring force in the required
direction and hold the lever against this force when
making the engagement stroke. The gear lever returns to
the neutral position if released in the central area.
3
5
1
8
N
4
6
2
12
Operation
002 694
CAUTION
To protect the transmission, always fully disengage the
clutch.
To avoid causing severe damage to the transmission and
engine, only change down a gear if the vehicle has been
braked to below the maximum speed for the intended
gear.
Move gear lever quickly but gently. This is particularly
important when the transmission oil is cold. It is best
to move the gear lever with the open palm of your
hand, as shown in Fig. 9.
When engaging a gear, hold the selector lever against
the pressure point until the synchronization process is
complete and the gear is engaged.
Double H
To move between gates 3/4 and 5/6, strike the gear
lever briefly with a palm of your hand, then moved
swiftly onwards into the desired gear (Fig. 9).
Fig. 9
Changing gates
when
upshifting
downshifting
002 701
NOTE
When the transmission is cold, gearshifting requires
increased shift effort. If the range-change group does
not change over when changing down from gate 5/6 into
gate 3/4, slow your vehicle and engage the appropriate
gear at a lower speed
CAUTION
Changing between gates 5/6 and 3/4 at a vehicle speed of
more than approx. 28 km/h is not permitted.
A gate change causes the rear-mounted range-change
group synchromesh to switch ranges and at vehicle speeds
of more than approx. 28 km/h, this will result in premature
wear.
13
Operation
Superimposed H
The range-change shift is pre-selected on the switch on
the shift lever. If, for example, drivers want to shift from
4th gear in the basic transmission into 5th gear, he must
7
3
5
1
high
8
4
N
6
2
Range-change group
017856/010877
shift the transmission to neutral the rangechange group then begins to change over
low
Fig. 9a
Reverse gear
CAUTION
Only engage reverse gear when the vehicle is at a standstill.
engage clutch
Reverse gear may only be selected or deselected
when the clutch is open.
14
Operation
NOTE
Service life periods differ depending on the
operating mode and may be reduced by short initial
synchromesh speed-matching, preferably of 1st gear.
CAUTION
Permanent shifting at high manual shift forces may result
in increased wear of synchronizer parts.
15
Operation
3.4
NOTE
Service life periods differ depending on the operating
mode and may be reduced by short initial synchromesh
speed-matching, preferably of 1st gear.
16
Operation
3.5
Parking
NOTE
When engaging the PTO, the following engine speeds
must not be exceeded:
2000 rpm for PTO ratio of 0.98
1300 rpm for PTO ratio of 1.55
depending on the inertia and drag torque levels to be
engaged.
NOTE
Refer to operating manual 1315 758 150.
3.6
a forwards gear
reverse gear
Tow-starting
Start the engine by towing with a gear engaged in the
high range-change group.
CAUTION
To prevent damage inside the transmission, only tow-start
the vehicle in the high range-change group (gears 5-8).
Furthermore, the vehicle must not be tow-started in
reverse gear.
17
Operation
3.7
Towing away
[i axle]
8.0
Rdyn 0.5[m](e.g.275/80R22.5)
7.0
Rdyn 0.6[m](e.g.F24)
6.0
Rdyn 0.4[m](e.g.245/70R19.5)
5.0
4.0
3.0
NOTE
Always observe instructions provided by the
vehicle manufacturer.
2.0
10
15
20
25
30
35
40
45
50
V [km/h]
CAUTION
If any of the above conditions are not fulfilled, the propshaft must be disconnected at the rear axle the stub shafts
must be removed.
If there is reason to suspect that the transmission unit is
damaged, disconnect the propeller shaft at the rear shaft
or remove the stub shafts.
18
Fig. 10
Example: iaxle= 6. Rdyn = 0.5 m
Towing speed according to diagram Vmax = 25 km/h
NOTE
Observe the relevant national legislation relating to
max. towing speeds.
Operation
3.8
Emergency operation
35
34
NOTE
Vehicle can then only be driven if the low rangechange group (1st 4th gear) is engaged.
If the high range-change group is engaged when the
fault occurs, the vehicle must be towed away.
Fig. 11
34 Shift cylinder for range-change group
35 Shift valve for range-change group
19
Operation
3.9
DANGER
When leaving vehicle with engine running, activate
parking brake. This prevents undesired vehicle
rolling.
NOTE
For engine starting and driving away, refer to
Section 3.1
The vehicle manufacturer specifications MUST
be observed.
20
Maintenance
Maintenance
First fill
11
13
13.5
Oil changes
10
11
Transmission oil
NOTE
Only oils contained in the valid ZF List of Lubricants
TE-ML 02 are authorized for use in the transmission.
The List of Lubricants can be obtained from all the ZF
After-Sales Service Centres or on the Internet under
www.zf.com.
21
Maintenance
4.2
Oil change
CAUTION
Oil must not be allowed to drain into the ground, into the
water table or into the sewage system. Any excess oil must
be collected in an appropriate
container and properly disposed of in accordance with
environment regulations.
NOTE
Always change the oil after a long journey so that the
transmission oil is still warm and thin.
017850
Fig. 12
View from below,
1 Oil drain plug (60 Nm)
2 Oil drain plug with magnetic plugs (60 Nm)
22
DANGER
Contact with the transmission or the transmission oil may lead to skin burns.
Unscrew oil drain plugs from transmission
(Fig. 12, items 1 and 2) and collect used oil in suitable
container.
Tighten the oil drain plugs (1) to the indicated torque.
Clean oil drain plug and magnetic plugs (2), replace
seal ring and tighten to the indicated torque.
Maintenance
4.3
Pour in the oil through the oil filler hole (Fig. 13).
The oil level is correct when the oil reaches the lower
edge of the filler hole or when oil is already escaping
out of the oil filler hole.
017083
Fig. 13
Position of oil filler hole and overflow measurement
If the oil level has fallen below the edge of the oil
filler hole, more oil must be added (Section 4.2.2).
NOTE
Every time you check the oil, also check the
transmission for any oil leaks.
23
Maintenance
4.4
Check:
- Allow engine to run at idling speed for approx.
3 minutes.
- Shift transmission into neutral.
- Switch off engine.
- Conduct oil level check has described under 4.3.
NOTE
Maintenance work relevant for the standard transmission version should be carried out.
The following points should also be noted:
Oil draining:
- Unscrew oil drain screw from heat exchanger.
Oil filling:
- After the oil overflow test (Section 4.2.2), screw in
the oil fill hole screw.
Tightening torque = 60 Nm.
- Shift transmission into neutral.
- Allow engine to run at approx. 1200 rpm for around
2 - 3 minutes. This is required to ensure that the heat
exchanger and connection pipes are filled completely
with oil.
- Switch off engine.
- Again top up with oil until it overflows.
24
Fig. 14
Diagram: Ecosplit transmission with heat exchanger
000 508
Maintenance
4.5
25
Maintenance
4.6
CAUTION
The lock synchronizer may be irreparably damaged if the
splitter group is engaged and the release valve is incorrectly
set.
17
37
To check
21
Fig. 15
26
a
b
c
d
17
19
21
32
37
19
32
Maintenance
4.7
Transmission breather
4.8
017083
Fig. 16
Transmission breather valve
27
Maintenance
4.9
Type plate
The type plate contains the most important transmission
data. It is located on the left side of the transmission (in
direction of drive).
Please always quote the following information in the
event of queries or repairs:
1. Transmission parts list no.
2. Transmission type
3. Transmission serial no.
ECOSPLIT
16 S 181
011356
XXXXXXX
16.41 - 1.0
13
Fig. 17
Sample type plate
28
IMP/U6.00
02
005001